US8181333B2 - Method of manufacturing squirrel-cage rotor - Google Patents
Method of manufacturing squirrel-cage rotor Download PDFInfo
- Publication number
- US8181333B2 US8181333B2 US12/407,210 US40721009A US8181333B2 US 8181333 B2 US8181333 B2 US 8181333B2 US 40721009 A US40721009 A US 40721009A US 8181333 B2 US8181333 B2 US 8181333B2
- Authority
- US
- United States
- Prior art keywords
- rotor
- rotor bars
- laminated stack
- end rings
- squirrel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related, expires
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000004512 die casting Methods 0.000 claims abstract description 9
- 239000000463 material Substances 0.000 claims description 17
- 229910000838 Al alloy Inorganic materials 0.000 claims description 11
- 238000003466 welding Methods 0.000 claims description 8
- 238000003756 stirring Methods 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 238000001125 extrusion Methods 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 238000009499 grossing Methods 0.000 claims 1
- 238000010030 laminating Methods 0.000 claims 1
- 229910052751 metal Inorganic materials 0.000 description 8
- 239000002184 metal Substances 0.000 description 8
- 238000000034 method Methods 0.000 description 7
- 230000002093 peripheral effect Effects 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 238000000465 moulding Methods 0.000 description 2
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/021—Magnetic cores
- H02K15/023—Cage rotors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0054—Casting in, on, or around objects which form part of the product rotors, stators for electrical motors
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49012—Rotor
Definitions
- the present disclosure relates to electric induction machines, and more particularly to methods of manufacturing squirrel-cage rotors for electric motors.
- Squirrel-cage rotors for electric induction machines may include a laminated stack that defines a plurality of elongated slots. A plurality of rotor bars are provided in the elongated slots. A pair of end rings are provided at opposite ends of the laminated stack.
- the laminated stack is placed in a set of molds that define cavities for forming the end rings. The cavities communicate with the elongated slots. A casting material is injected into the set of molds and fills in the cavities to form the end rings and the elongated slots to form the rotor bars.
- die-casting the rotor bars and the end rings concurrently in the same set of molds increases the complexity of the molding process.
- shrinkage holes may be formed in the interior of the elongated slots and the end rings. The shrinkage holes affect integrity of the rotor bars and the end rings. Further, die-casting the rotor bars and the end rings in the same set of molds is more expensive and die wear generally occurs when the die-cast rotor assembly is removed from the molds.
- a method of manufacturing a squirrel-cage rotor includes: providing a laminated stack; attaching a plurality of rotor bars to the laminated stack, wherein the plurality of rotor bars each include opposite longitudinal ends; and die-casting a pair of end rings at the longitudinal ends of the plurality of rotor bars.
- a squirrel-cage rotor includes a laminated stack, a plurality of rotor bars, and a pair of end rings.
- the plurality of rotor bars are attached to the laminated stack and are made of a first material.
- the pair of end rings are attached to longitudinal ends of the laminated stack and are made of a second material.
- the second material is a casting material.
- the first material is different from the second material.
- the laminated stack includes a plurality of steel sheets.
- the plurality of rotor bars are extruded and include aluminum alloy 6101.
- the end rings are produced by die-casting aluminum alloy 6061.
- FIG. 1 is a plan view of a squirrel-cage rotor in accordance with the teachings of the present disclosure
- FIG. 2 is a cross-sectional view of a squirrel-cage rotor in accordance with the teachings of the present disclosure
- FIG. 3 is a perspective view of a laminated stack of a squirrel-cage rotor in accordance with the teachings of the present disclosure
- FIG. 4 is a top view of a metal sheet of a squirrel-cage rotor in accordance with the teachings of the present disclosure
- FIG. 5 is a top view of a variant of a metal sheet of a squirrel-cage rotor in accordance with the teachings of the present disclosure.
- FIG. 6 is a flow diagram illustrating a method of manufacturing a squirrel-cage rotor in accordance with the teachings of the present disclosure.
- a method of manufacturing a squirrel-cage rotor in accordance with the teachings of the present disclosure includes inserting a plurality of preformed rotor bars to a laminated stack, followed by die-casting the end rings.
- the rotor bars and the end rings are manufactured by different manufacturing methods, resulting in increased selection of available materials and reduced molding expenses.
- an exemplary squirrel-cage rotor 10 for an electric induction machine includes a laminated stack 14 , a plurality of rotor bars 16 inserted into the laminated stack 14 , and a pair of end rings 18 provided at longitudinal ends of the laminated stack 14 .
- the laminated stack 14 may be mounted around a rotatable shaft 21 .
- the rotor bars 16 include longitudinal ends 20 that protrude beyond the longitudinal ends of the laminated stack 14 and that are inserted into the end rings 18 .
- the laminated stack 14 abuts against the end rings 18 .
- Weld joints 22 are formed at interfaces between the rotor bars 16 and the end rings 18 .
- the weld joints 22 may be formed at peripheries of the rotor bars 16 adjacent to the end rings 18 and along the entire surfaces of the rotor bars 16 inside the end rings 18 .
- the laminated stack 14 includes a central slot 26 and a plurality of elongated slots 28 .
- the rotatable shaft 21 may be inserted into the central slot 26 .
- the elongated slots 28 are provided adjacent to the periphery of the laminated stack 14 and may extend axially along the entire length of the laminated stack 28 .
- the elongated slots 28 may extend in a direction parallel to a central axis of the laminated stack 14 .
- the elongated slots 28 may be skewed relative to the end rings 18 .
- the plurality of rotor bars 16 are inserted into the elongated slots 28 .
- the laminated stack 14 includes a plurality of metal sheets 24 that are made of, for example only, steel.
- the plurality of metal sheets 24 are laminated along the central axis of the laminated stack 14 and each have a central opening 30 and a plurality of peripheral apertures 32 .
- the central openings 30 of the plurality of metal sheets 24 jointly define the central slot 26 for the rotatable shaft 21 .
- the plurality of apertures 32 are circumferentially spaced apart and jointly define the elongated slots 28 .
- the peripheral apertures 32 may have a shape and size conforming to the shape and size of the rotor bars 16 .
- a variant form of a metal sheet 40 may include a central opening 42 and a plurality of cutouts 44 that are open to the peripheral edges. It is noted that the apertures 32 and the cutouts 44 of FIGS. 4 and 5 , respectively, are shown for illustration only and the number of the apertures 28 and the cutouts 44 may not be consistent with the number elongated slots illustrated in FIG. 3 .
- the rotor bars 16 and the end rings are formed with electrically conductive materials.
- the rotor bars 16 and the end rings 18 may include, for example only, copper alloy or aluminum alloy.
- the rotor bars 16 may be formed, for example only, by extrusion, stamping or machining.
- the end rings 28 may be formed, for example only, by die casting.
- the rotor bars 16 may be produced in extruded rods made of aluminum alloy 6101 and the end rings may be produced by die-casting aluminum alloy 6061.
- Aluminum alloy 6101 has greater electrical conductivity than aluminum alloy 6061, whereas aluminum alloy 6061 has greater mechanical strength than aluminum alloy 6101.
- a method 70 of manufacturing a squirrel-cage rotor starts in step 72 .
- a plurality of metal sheets are laminated to form a laminated stack in step 74 .
- the central openings of the metal sheets are aligned to form a central slot for the rotatable shaft.
- the peripheral apertures are aligned to form a plurality of bar slots.
- a plurality of rotor bars are pre-formed, for example only, by extrusion in step 76 .
- the preformed rotor bars are inserted into the bar slots to form a sub-assembly in step 78 .
- the longitudinal ends of the rotor bars protrude from the longitudinal ends of the laminated stack.
- the sub-assembly is placed in a set of die cast molds that define cavities for forming end rings in step 80 .
- a molten casting material is injected into the die cast molds to fill in the cavities in step 82 .
- the end rings are formed and may be partially joined to the rotor bars 16 .
- the rotor assembly that includes the rotor core 14 , the rotor bars 16 , and the end rings 18 is removed from the molds in step 84 .
- Stir-welding is applied to the interfaces between the rotor bars 16 and the end rings 18 in step 86 .
- a welding fixture (not shown) may be used to retain the end rings 18 in position relative to the longitudinal ends 20 of the rotor bars 16 .
- the rotor bars 16 are placed perpendicular to the end rings 18 and are inserted into the end rings 18 .
- Stir welding is a solid-state joining process wherein frictional heat is generated to cause opposed portions of workpieces to take up a plasticized condition. When a spinning probe that causes the frictional heat is removed, the plasticized portions solidify and join the workpieces.
- the weld joints 22 may be formed by stir-welding and may be formed at the interface between the rotor bars 16 and the end rings 18 . For example only, the weld joints 22 may be formed around the circumference of the end rings 18 and/or peripheries of the rotor bars 16 .
- the end rings 18 are later machined to provide smooth weld joints in step 88 . If the end rings 18 have an outside diameter greater than that of the laminated stack 14 , the end rings 18 may be machined to have an outside diameter approximate to the outside diameter of the laminated stack.
- the method 70 ends in the step 90 .
- the squirrel-cage rotor manufactured by the method of the present disclosure has preformed rotor bars and die-cast end rings.
- the rotor bars may be made of a material that has a greater electrical conductivity than that of the end rings. Therefore, the method of manufacturing a squirrel-cage rotor according to the present disclosure allows for wide selection of materials while increasing integrity of the rotor bars and the end rings.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Induction Machinery (AREA)
Abstract
Description
Claims (1)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/407,210 US8181333B2 (en) | 2008-07-09 | 2009-03-19 | Method of manufacturing squirrel-cage rotor |
DE102009031345A DE102009031345A1 (en) | 2008-07-09 | 2009-07-01 | Squirrel cage and methods of making them |
CN2009101402222A CN101626179B (en) | 2008-07-09 | 2009-07-09 | Squirrel-cage rotors and methods of manufacturing same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US7919208P | 2008-07-09 | 2008-07-09 | |
US12/407,210 US8181333B2 (en) | 2008-07-09 | 2009-03-19 | Method of manufacturing squirrel-cage rotor |
Publications (2)
Publication Number | Publication Date |
---|---|
US20100007234A1 US20100007234A1 (en) | 2010-01-14 |
US8181333B2 true US8181333B2 (en) | 2012-05-22 |
Family
ID=41504536
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/407,210 Expired - Fee Related US8181333B2 (en) | 2008-07-09 | 2009-03-19 | Method of manufacturing squirrel-cage rotor |
Country Status (3)
Country | Link |
---|---|
US (1) | US8181333B2 (en) |
CN (1) | CN101626179B (en) |
DE (1) | DE102009031345A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120210563A1 (en) * | 2011-02-23 | 2012-08-23 | GM Global Technology Operations LLC | Method of manufacturing an end ring over pre-formed conductor bars of a rotor for an electric device |
EP3113340A4 (en) * | 2014-02-28 | 2017-10-25 | NHK Spring Co., Ltd. | Rotor and method for manufacturing same |
Families Citing this family (24)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8448328B2 (en) | 2010-01-06 | 2013-05-28 | GM Global Technology Operations LLC | Methods of making aluminum based composite squirrel cage for induction rotor |
US8701270B2 (en) | 2010-01-21 | 2014-04-22 | GM Global Technology Operations LLC | Methods of manufacturing induction rotors with conductor bars having high conductivity |
US8312914B2 (en) | 2010-05-24 | 2012-11-20 | GM Global Technology Operations LLC | Method, mold, and mold system for forming rotors |
US8344577B2 (en) * | 2010-08-31 | 2013-01-01 | GM Global Technology Operations LLC | Solid phase welding of aluminum-based rotors for induction electric motors |
US20120126656A1 (en) * | 2010-11-24 | 2012-05-24 | Gm Global Technology Operations, Inc. | Rotor assembly and method of manufacturing a rotor assembly |
FI122755B (en) * | 2011-01-26 | 2012-06-29 | Axco Motors Oy | Dressing and dressing procedure in a permanent magnet synchronous machine |
CN102624163A (en) * | 2011-01-28 | 2012-08-01 | 福建金隆动力机电有限公司 | Manufacturing method of salient pole rotor |
US8910371B2 (en) * | 2011-02-28 | 2014-12-16 | GM Global Technology Operations LLC | Method for fabricating an induction rotor |
JP5155420B2 (en) * | 2011-03-11 | 2013-03-06 | ファナック株式会社 | Cage rotor of induction motor for brazing end ring and bar and manufacturing method thereof |
JP5562307B2 (en) * | 2011-08-30 | 2014-07-30 | 日立オートモティブシステムズ株式会社 | Cage rotor and rotating electric machine |
JP5851887B2 (en) * | 2012-03-02 | 2016-02-03 | 株式会社神戸製鋼所 | Rotor for induction torque motor and induction torque motor |
DE102013221533A1 (en) * | 2012-10-26 | 2014-04-30 | GM Global Technology Operations, LLC (n.d. Ges. d. Staates Delaware) | Method for fabricating e.g. high performance rotor of alternating current induction motor for motor vehicle, involves casting portion of conductive material over exposed ends to form shorting end ring to mechanically connect conductor bars |
US9601978B2 (en) | 2013-04-26 | 2017-03-21 | GM Global Technology Operations LLC | Aluminum alloy rotor for an electromagnetic device |
JP2015162913A (en) * | 2014-02-26 | 2015-09-07 | 住友重機械工業株式会社 | Induction motor and manufacturing method of rotor thereof |
CN103887934B (en) * | 2014-04-24 | 2016-08-17 | 洛阳轴研科技股份有限公司 | A kind of method for fine finishing of electro spindle cage rotor |
CN104526262A (en) * | 2014-11-04 | 2015-04-22 | 江西华电电力有限责任公司 | Method and product for manufacturing lamination type screw rotor |
CN107819366A (en) * | 2016-09-14 | 2018-03-20 | 上海蔚兰动力科技有限公司 | The rotor and its manufacture method of induction conductivity |
EP3382864A1 (en) | 2017-03-29 | 2018-10-03 | Siemens Aktiengesellschaft | Hybrid cage rotor |
CN107579609A (en) * | 2017-09-01 | 2018-01-12 | 北京动力源科技股份有限公司 | A kind of rotor squirrel cage and processing method |
DE102017219704A1 (en) * | 2017-11-07 | 2019-05-09 | Bayerische Motoren Werke Aktiengesellschaft | Method for producing a component |
CN108448851A (en) * | 2018-05-18 | 2018-08-24 | 永济市贝特电气机械有限公司 | A kind of rotor cage of squirrel-cage motor |
CN113556011B (en) * | 2021-08-04 | 2022-05-24 | 永济市贝特电气机械有限公司 | A method of making a motor rotor squirrel cage |
DE102022212315B4 (en) | 2022-11-18 | 2024-10-17 | Zf Friedrichshafen Ag | Method for producing a rotor of an electrical machine and rotor |
DE102022212320B4 (en) | 2022-11-18 | 2024-08-01 | Zf Friedrichshafen Ag | Method for producing a rotor of an electrical machine and rotor |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2784333A (en) * | 1953-08-03 | 1957-03-05 | Reliance Electric & Eng Co | Cast rotor and method |
JPS5454209A (en) * | 1977-10-07 | 1979-04-28 | Toshiba Corp | Method of manufacturing aluminum casting rotor of revolving electric machine |
US5990595A (en) * | 1996-10-04 | 1999-11-23 | General Electric Company | Rotors and methods of manufacturing such rotors |
EP1347560A1 (en) | 2000-12-27 | 2003-09-24 | Hitachi, Ltd. | Dynamo-electric machine |
US7791240B2 (en) * | 2007-07-27 | 2010-09-07 | Gm Global Technology Operations, Inc. | Stir-welded rotors and methods of making |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN2862483Y (en) * | 2005-10-31 | 2007-01-24 | 上海日立电器有限公司 | Rotor structure for asynchrony-started permanent magnetic synchrony motor |
-
2009
- 2009-03-19 US US12/407,210 patent/US8181333B2/en not_active Expired - Fee Related
- 2009-07-01 DE DE102009031345A patent/DE102009031345A1/en not_active Withdrawn
- 2009-07-09 CN CN2009101402222A patent/CN101626179B/en not_active Expired - Fee Related
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2784333A (en) * | 1953-08-03 | 1957-03-05 | Reliance Electric & Eng Co | Cast rotor and method |
JPS5454209A (en) * | 1977-10-07 | 1979-04-28 | Toshiba Corp | Method of manufacturing aluminum casting rotor of revolving electric machine |
US5990595A (en) * | 1996-10-04 | 1999-11-23 | General Electric Company | Rotors and methods of manufacturing such rotors |
EP1347560A1 (en) | 2000-12-27 | 2003-09-24 | Hitachi, Ltd. | Dynamo-electric machine |
US7791240B2 (en) * | 2007-07-27 | 2010-09-07 | Gm Global Technology Operations, Inc. | Stir-welded rotors and methods of making |
Non-Patent Citations (1)
Title |
---|
Full Translation of JP54054209A, 13 pages. * |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120210563A1 (en) * | 2011-02-23 | 2012-08-23 | GM Global Technology Operations LLC | Method of manufacturing an end ring over pre-formed conductor bars of a rotor for an electric device |
US8424188B2 (en) * | 2011-02-23 | 2013-04-23 | GM Global Technology Operations LLC | Method of manufacturing an end ring over pre-formed conductor bars of a rotor for an electric device |
EP3113340A4 (en) * | 2014-02-28 | 2017-10-25 | NHK Spring Co., Ltd. | Rotor and method for manufacturing same |
US10505432B2 (en) | 2014-02-28 | 2019-12-10 | Nhk Spring Co., Ltd. | Rotor and method for manufacturing rotor |
Also Published As
Publication number | Publication date |
---|---|
DE102009031345A1 (en) | 2010-04-01 |
CN101626179B (en) | 2012-12-26 |
US20100007234A1 (en) | 2010-01-14 |
CN101626179A (en) | 2010-01-13 |
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